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Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW100-6

Hitachi ZW100-6 Troubleshooting

The Hitachi ZW100-6 wheel loader is powered by 221 cu.in (3.6L) Deutz TCD3.6L4F 4-cylinder direct injection turbocharged liquid-cooled diesel engine with a rated power of 96 hp (71 kW) at 2000 rpm. The Hitachi ZW100-6 is equipped with a hydro transmission with powershift gearbox, hydraulic power steering, hydraulic wet disc brakes, and 16.9x24 standard tires. The hydraulic system has a gear pump with fluid flow rate of 32 gpm (121 lpm). The wheel loader has a rated operating capacity of 5510 lbs (2505 kg) and tipping load of 11020 lbs (5010 kg). The max lift height is 138.4 inches (3515 mm) to hinge pin, and boom breakout force is 13730 lbs (6240 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start
There is air in the fuel system - Bleed the system.
Dirty fuel filter - Change filter element.
Faulty or dirty injection nozzles - Install a new kit of correctly balanced nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve out of adjustment - Adjustment procedure required.
Fuel injection pump malfunction - Repair or install a new fuel pump.

Engine starts and stops suddenly
Plugged air cleaner - Clean or change cleaner.
Fuel filter element clogging - Clean or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Fuel injection pump failure - Install a new pump or rebuild.

Engine shuts off suddenly while running
Engine is not warmed up to required temperature - Warm up engine as required.
Fuel filter element clogging - Replace filter element.
Air in the fuel system - Air bleeding.
Clogged or burnt injection nozzle - Clean or change injection nozzles.
Fuel injection pump timing is wrong - Adjust the pump as required.

Engine stalls while idling
Improperly adjusted low idle speed - Need to adjust idle speed.
Faulty fuel injection pump - Repair or install new pump.
Fuel injector fault - Inspect fuel injectors and change as required.
Valve out of adjustment - Adjustment procedure required.

Engine lacks power
Dirty air filter - Install new air filter element.
Clogged injection nozzle - Test injection nozzles and change if necessary.
Fuel injection pressure is wrong - Adjust pressure to proper level.
Valve clearance is not correct - Have it adjusted.
Low idle speed setting is not correct - Adjustment required.
Fuel lines or hoses are dirty - Service fuel hoses and lines.
Cylinder-head gasket is broken - Replace cylinder head gasket.
Piston rings are worn or defective - Replace piston rings.

Engine overheats
Not enough coolant - Top up coolant fluid and check system for leaks.
Not enough engine oil - Fill up the engine oil.
Dirty radiator core or faulty radiator cap - Clean radiator or replace cap.
Fan belt is loose or defective - Belt change is required.
Engine is under excessive load - Load reducing is recommended.

Oil pressure is low
Not enough oil in the engine - Add oil as required.
Oil filter clogged - Change or service engine oil filter.
Incorrect oil viscosity - Use the specified type of engine oil.
Excessive oil clearance of crankshaft bearing - Bearing replacement required.
Oil pump malfunction - Remove and inspect oil pump.

Engine noises or knocks
Lack of engine oil - Check and refill engine oil.
Engine is not warmed up to required temperature - Normalize the temperature by warming up the engine.
Wrong setting of fuel injection pump timing - Set the fuel pump timing correctly.
Improperly adjusted low idle speed - Adjustment required.
Fuel injector fault - Replace fuel injectors.
Faulty or misaligned connecting rod - Align or replace connecting rod.
Pistons are worn or scored - Pistons need to be replaced.

Transmission Troubleshooting

Transmission oil pressure is low
Transmission oil insufficient - Fill the transmission housing to proper oil level.
Plugged transmission oil filter (if equipped) - Service or replace the transmission oil filter.
Stuck relief valve - Install a new relief valve.

Transmission makes noise
Transmission oil level is low - Check and refill the transmission oil.
Transmission fluid contamination - Change the fluid.
Incorrect backlash or gears are worn - Adjust backlash correctly or replace the gears.
Worn or cracked bearings - Change the bearings.
Shift forks are bent or worn out - Shift forks need to be replaced.
Stuck or worn shaft splines - Replace the shaft.

Gears are hard to shift
Gear shift linkage is corroded or worn - Lubricate or replace the shift linkage.
Damaged or worn gear shift forks - Replace defective shift forks.
Worn gear shifting mechanism - Repair or change worn components if necessary.
Improperly adjusted or worn clutch - Clutch replacement or adjustment required.

Transmission oil leaking
Transmission oil level is high - Correct the oil volume.
Seals or gaskets are worn - Install new seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure incorrectly adjusted - Adjust pressure correctly.
Main relief valve malfunction or improper adjustment - Adjust the valve or replace if necessary.
Hydraulic fluid is dirty - The fluid must be changed.
Lack of hydraulic oil - Add oil to the hydraulic system.
Faulty hydraulic oil pump - Change or repair hydraulic pump if required.

Lift arm fails to drop or lift
Defective lift controls - Inspect and repair if necessary.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve failure - Install a new hydraulic valve or repair it.
Hydraulic cylinder is defective - Change or repair lift cylinder.
Hydraulic oil level low - Need to add oil.

Bucket can't tilt
Bucket controls failure - Replace or repair.
Hydraulic pump failure - Repair or change pump if required.
Defective hydraulic control valve - Replace or repair the valve.
Defective bucket cylinder - Repair or install a new cylinder.
Hydraulic oil is insufficient - Need to add oil.

Bucket or lift arm runs slowly
Worn hydraulic oil pump - Flow-rate hydraulic pump and replace pump if necessary.
Hydraulic cylinder oil leakage - Change cylinder piston seals.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is faulty or out of adjustment - Adjust correctly or repair.
Hydraulic pressure loss - Adjust it correctly.

Bucket or boom movements are jerky
There is air in the hydraulic system - Bleed air from system.
Dirty hydraulic oil filter - Clean or replace the filter.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Cylinder tube or rod is scored - Replace defective component.

Hydraulic pump makes excessive noise
Hydraulic leaks or lack of oil - Add hydraulic oil or correct system leaks.
Hydraulic filter is clogged - Service or change hydraulic filter.
Suction line clogging - Need to clean the suction line.
Air in hydraulic pump - Air bleeding is required.
Damaged pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery won’t charge
Loose or corroded cable connections - Clean or tighten wiring connections.
Defective battery terminal clamps - Terminal clamps need to be replaced.
Battery bad cell - Change the battery.
Belt is defective or loose - Adjust belt tension or replace belt.

Starter motor cranks slow
Low battery voltage - Recharge the battery.
Battery runs out quickly - Service or change the battery.
Corroded battery terminals or disconnected wires - Check cables and service or change terminals.

Starter is not cranking
Battery is discharged or worn - Change or recharge battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery voltage - Battery is drained, recharge it.
Damaged starter motor - Starter should be replaced.

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